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Energy optimization is a hot research topic for design and operation of crude oil distillation plants. Optimum energy utilization in a multistage crude oil distillation process is achieved by optimizing the distillation load of each distillation column as well as the yield of the sidestreams of distillation columns. A generalized multistage distillation energy consumption model is proposed, and the optimal distillation load distribution is accomplished by minimizing the total energy consumption. Based on the optimal distillation loads, a nonlinear programming model is then formulated to determine the yields of sidestreams by maximizing the thermal exergy recovery for the crude oil plant. Finally, a four-stage crude oil distillation plant is investigated to demonstrate the performance of the proposed approach. The results show a decrease in energy consumption and an increase in heat recovery.

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